Fin field effect transistor (FinFET) device and method

ABSTRACT

A FinFET device structure is provided. The FinFET device structure includes an isolation structure formed over a substrate and a fin structure formed over the substrate. The FinFET device structure includes a first gate structure and a second gate structure formed over the fin structure, and the first gate structure has a first width in a direction parallel to the fin structure, the second gate structure has a second width in a direction parallel to the fin structure, and the first width is smaller than the second width. The first gate structure includes a first work function layer having a first height. The second gate structure includes a second work function layer having a second height and a gap between the first height and the second height is in a range from about 1 nm to about 6 nm.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a continuation of U.S. patent application Ser. No. 15/445,664, filed on Feb. 28, 2017, and entitled “Fin Field Effect Transistor (FinFET) Device Structure with Uneven Gate Structure” which is a divisional of U.S. patent application Ser. No. 14/737,066, filed on Jun. 11, 2015, (now U.S. Pat. No. 9,583,485, issued Feb. 28, 2017) and entitled “Fin Field Effect Transistor (FinFET) Device Structure with Uneven Gate Structure and Method for Forming the Same” which claims priority to U.S. Provisional Patent Application No. 62/165,569 filed May 22, 2015, and entitled “Fin Field Effect Transistor (FinFET) Device Structure with Uneven Gate Structure and Method for Forming the Same,” which applications are incorporated herein by reference.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications, such as personal computers, cell phones, digital cameras, and other electronic equipment. Semiconductor devices are typically fabricated by sequentially depositing insulating or dielectric layers, conductive layers, and semiconductive layers of material over a semiconductor substrate, and patterning the various material layers using lithography to form circuit components and elements thereon. Many integrated circuits are typically manufactured on a single semiconductor wafer, and individual dies on the wafer are singulated by sawing between the integrated circuits along a scribe line. The individual dies are typically packaged separately, in multi-chip modules, for example, or in other types of packaging.

As the semiconductor industry has progressed into nanometer technology process nodes in pursuit of higher device density, higher performance, and lower costs, challenges from both fabrication and design issues have resulted in the development of three-dimensional designs, such as the fin field effect transistor (FinFET). FinFETs are fabricated with a thin vertical “fin” (or fin structure) extending from a substrate. The channel of the FinFET is formed in this vertical fin. A gate is provided over the fin. Advantages of the FinFET may include reducing the short channel effect and providing a higher current flow.

Although existing FinFET devices and methods of fabricating FinFET devices have generally been adequate for their intended purpose, they have not been entirely satisfactory in all respects.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It should be noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIGS. 1A-1H show perspective representations of various stages of forming a FinFET device structure, in accordance with some embodiments of the disclosure.

FIGS. 2A-2J show cross-sectional representations of various stages of forming a FinFET device structure shown in FIG. 1G-1H, in accordance with some embodiments of the disclosure.

FIG. 3 shows a bias power (W) versus an operation time (seconds) of a first plasma operation and a second plasma operation, in accordance with some embodiments.

FIG. 4 shows a perspective representation of a FinFET device structure, in accordance with some embodiments of the disclosure.

FIGS. 5A-5E show a perspective representations of various stages of forming a FinFET device structure, in accordance with some embodiments of the disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the subject matter provided. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Some variations of the embodiments are described. Throughout the various views and illustrative embodiments, like reference numbers are used to designate like elements. It should be understood that additional operations can be provided before, during, and after the method, and some of the operations described can be replaced or eliminated for other embodiments of the method.

Embodiments for forming a fin field effect transistor (FinFET) device structure are provided. FIGS. 1A-1H show perspective representations of various stages of forming a FinFET device structure 100, in accordance with some embodiments of the disclosure.

Referring to FIG. 1A, a substrate 102 is provided. The substrate 102 may be made of silicon or other semiconductor materials. Alternatively or additionally, the substrate 102 may include other elementary semiconductor materials such as germanium. In some embodiments, the substrate 102 is made of a compound semiconductor such as silicon carbide, gallium arsenic, indium arsenide, or indium phosphide. In some embodiments, the substrate 102 is made of an alloy semiconductor such as silicon germanium, silicon germanium carbide, gallium arsenic phosphide, or gallium indium phosphide. In some embodiments, the substrate 102 includes an epitaxial layer. For example, the substrate 102 has an epitaxial layer overlying a bulk semiconductor.

Afterwards, a dielectric layer 104 and a mask layer 106 are formed over the substrate 102, and a photoresist layer 108 is formed over the mask layer 106. The photoresist layer 108 is patterned by a patterning process. The patterning process includes a photolithography process and an etching process. The photolithography process includes photoresist coating (e.g., spin-on coating), soft baking, mask aligning, exposure, post-exposure baking, developing the photoresist, rinsing and drying (e.g., hard baking). The etching process includes a dry etching process or a wet etching process.

The dielectric layer 104 is a buffer layer between the substrate 102 and the mask layer 106. In addition, the dielectric layer 104 is used as a stop layer when the mask layer 106 is removed. The dielectric layer 104 may be made of silicon oxide. The mask layer 106 may be made of silicon oxide, silicon nitride, silicon oxynitride, or another applicable material. In some other embodiments, more than one mask layer 106 is formed over the dielectric layer 104.

The dielectric layer 104 and the mask layer 106 are formed by deposition processes, such as a chemical vapor deposition (CVD) process, high-density plasma chemical vapor deposition (HDPCVD) process, spin-on process, sputtering process, or another applicable process.

After the photoresist layer 108 is patterned, the dielectric layer 104 and the mask layer 106 are patterned by using the patterned photoresist layer 108 as a mask as shown in FIG. 1B, in accordance with some embodiments. As a result, a patterned pad layer 104 and a patterned mask layer 106 are obtained. Afterwards, the patterned photoresist layer 108 is removed.

Afterwards, an etching process is performed on the substrate 102 to form a fin structure 110 by using the patterned dielectric layer 104 and the patterned mask layer 106 as a mask. The etching process may be a dry etching process or a wet etching process.

In some embodiments, the substrate 102 is etched by a dry etching process. The dry etching process includes using the fluorine-based etchant gas, such as SF₆, C_(x)F_(y), NF₃ or combinations thereof. The etching process may be a time-controlled process, and continue until the fin structure 110 reach a predetermined height. In some other embodiments, the fin structure 110 has a width that gradually increases from the top portion to the lower portion.

After the fin structure 110 is formed, the patterned dielectric layer 104 and the patterned mask layer 106 are removed. An insulating layer 112 is formed to cover the fin structure 110 over the substrate 102 as shown in FIG. 1C, in accordance with some embodiments.

In some embodiments, the insulating layer 112 is made of silicon oxide, silicon nitride, silicon oxynitride, fluoride-doped silicate glass (FSG), or another low-k dielectric material. The insulating layer 112 may be deposited by a chemical vapor deposition (CVD) process, a spin-on-glass process, or another applicable process.

Afterwards, the insulating layer 112 is thinned or planarized to expose the top surface of the fin structure 110 as shown in FIG. 1D, in accordance with some embodiments. In some embodiments, the insulating layer 112 is thinned by a chemical mechanical polishing (CMP) process.

As a result, an isolation structure 114, such as a shallow trench isolation (STI) structure, surrounds the fin structure 110. A lower portion of the fin structure 110 is surrounded by the isolation structure 114, and an upper portion of the fin structure 110 protrudes from the isolation structure 114. In other words, a portion of the fin structure 110 is embedded in the isolation structure 114. The isolation structure 114 prevents electrical interference or crosstalk.

Afterwards, a first dummy gate structure 116 a and a second dummy gate structure 116 b are formed across the fin structure 110 and extends over the isolation structure 114 as shown in FIG. 1E, in accordance with some embodiments. The first dummy gate structure 116 a is formed in a first region 11 and the second dummy gate structure 116 b is formed in a second region 12.

In some embodiments, the first dummy gate structure 116 a includes a first dummy gate dielectric layer 118 a and a first dummy gate electrode layer 120 a formed over the first dummy gate dielectric layer 118 a. In some embodiments, the second dummy gate structure 116 b includes a second dummy gate dielectric layer 118 b and a second dummy gate electrode layer 120 b formed over the second dummy gate dielectric layer 118 b.

After the first dummy gate structure 116 a and the second dummy gate structure 116 b are formed, first spacers 122 a are formed on the opposite sidewalls of the first dummy gate structure 116 a, and second spacers 122 b are formed on the opposite sidewalls of the second dummy gate structure 116 b. The first spacers 122 a and the second spacers 122 b may be a single layer or multiple layers.

In some embodiments, the first dummy gate structure 116 a has a first width W₁ in a direction parallel to the fin structure 110, and the second dummy gate structure 116 b has a second width W₂ in a direction parallel to the fin structure 110. In other words, the first width W₁ is measured from an edge of the first spacers 122 a to an edge of the opposite first spacer 122 a. The second width W₂ is measured from an edge of the second spacers 122 b to an edge of the opposite second spacer 122 b. The first width W₁ is smaller than the second width W₂.

Afterwards, source/drain (S/D) structures 124 are formed in the fin structure 110. In some embodiments, portions of the fin structure 110 adjacent to the first dummy gate structure 116 a and the second dummy gate structure 116 b are recessed to form recesses at two sides of fin structure 110, and a strained material is grown in the recesses by an epitaxial (epi) process to form the source/drain (S/D) structures 124. In addition, the lattice constant of the strained material may be different from the lattice constant of the substrate 102. In some embodiments, the source/drain structures 124 include Ge, SiGe, InAs, InGaAs, InSb, GaAs, GaSb, InAlP, InP, or the like.

After the source/drain structures 124 are formed, a contact etch stop layer (CESL) 126 is formed over the substrate 102, and an inter-layer dielectric (ILD) structure 128 is formed over the contact etch stop layer 126 as shown in FIG. 1F, in accordance with some embodiments. In some embodiments, the contact etch stop layer 126 is made of silicon nitride, silicon oxynitride, and/or other applicable materials. The contact etch stop layer 126 may be formed by plasma enhanced CVD, low pressure CVD, ALD, or other applicable processes.

The ILD structure 128 may include multilayers made of multiple dielectric materials, such as silicon oxide, silicon nitride, silicon oxynitride, tetraethoxysilane (TEOS), phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), low-k dielectric material, and/or other applicable dielectric materials. Examples of low-k dielectric materials include, but are not limited to, fluorinated silica glass (FSG), carbon doped silicon oxide, amorphous fluorinated carbon, parylene, bis-benzocyclobutenes (BCB), or polyimide. The ILD structure 128 may be formed by chemical vapor deposition (CVD), physical vapor deposition, (PVD), atomic layer deposition (ALD), spin-on coating, or other applicable processes.

Afterwards, a polishing process is performed to the ILD structure 128 until the top surface of the first dummy gate structure 116 a and the top surface of the second dummy gate structure 116 bare exposed. In some embodiments, the ILD structure 128 is planarized by a chemical mechanical polishing (CMP) process.

After the ILD structure 128 is formed, the first dummy gate structure 116 a is removed to form a first trench 130 a in the ILD structure 128 and the second dummy gate structure 116 b is removed to form a second trench 130 b in the ILD structure 128 as shown in FIG. 1G, in accordance with some embodiments. The first dummy gate structure 116 a and the second dummy gate structure 116 b may be removed by a wet etching process or a dry etching process.

After the first trench 130 a and the second trench 130 b are formed, a first etched gate structure 132′a and a second etched gate structure 132′b are formed in the first trench 130 a and the second trench 130 b, respectively, as shown in FIG. 1H, in accordance with some embodiments.

The first etched gate structure 132′a includes a first etched gate dielectric layer 134′a, a first etched work function layer 136′a and a first gate electrode layer 138′a. The second etched gate structure 132′b includes a second etched gate dielectric layer 134′b, a second etched work function layer 136′b and a second gate electrode layer 138′b. The first etched gate structure 132′a has an unleveled top surface, and the second etched gate structure 132′b has an unleveled top surface.

A first hard mask structure 152 a is formed over the first etched gate structure 132′a, and a second hardmask layer 152 b is formed over the second etched gate structure 132′b. The first hard mask structure 152 a includes a first portion 154 a, a second portion 156 a and a third portion 158 a, and the thicknesses of the portion 154 a, the second portion 156 a and the third portion 158 a are different.

FIGS. 2A-2J show cross-sectional representations of various stages of forming a FinFET device structure shown in FIG. 1G-1H, in accordance with some embodiments of the disclosure. FIG. 2A is a cross-sectional representation taken along the II′ line of FIG. 1G.

Referring to FIG. 2A, the first trench 130 a is formed between the first spacers 122 a in the first region 11, and the second spacers 130 b is formed between the second spacers 122 b in the second region 12. The first trench 130 a has a third width W₃ in a direction parallel to the fin structure 110, and the second trench has a fourth width W₄ in a direction parallel to the fin structure 110. Third width W₃ is substantially equal to the first width W₁ (shown in FIG. 1E). The fourth width W₄ is substantially equal to the second width W₂ (shown in FIG. 1E).

The third width W₃ is smaller than the fourth width W₄. The fourth width W₄ is greater than the third width W₃. In some embodiments, the third width W₃ is in a range from about 10 nm to about 100 nm. In some embodiments, the fourth width W₄ is in a range from about 101 nm to about 500 nm.

After the first trench 130 a and the second trench 130 b are formed, a gate dielectric layer 134 is conformally formed in the first trench 130 a and the second trench 130 b as shown in FIG. 2B, in accordance with some embodiments. More specifically, the gate dielectric layer 134 is formed over bottom surfaces and sidewalls of the first trench 130 a and the second trench 130 b, and over the inter-layer dielectric (ILD) structure 128.

The gate dielectric layer 134 may be a single layer or multiple layers. The gate dielectric layer 134 is made of silicon oxide (SiO_(x)), silicon nitride (Si_(x)N_(y)), silicon oxynitride (SiON), dielectric material(s) with low dielectric constant (low-k), or combinations thereof. In some embodiments, the gate dielectric layer 134 is made of an extreme low-k (ELK) dielectric material with a dielectric constant (k) less than about 2.5. In some embodiments, ELK dielectric materials include carbon doped silicon oxide, amorphous fluorinated carbon, parylene, bis-benzocyclobutenes (BCB), polytetrafluoroethylene (PTFE) (Teflon), or silicon oxycarbide polymers (SiOC). In some embodiments, ELK dielectric materials include a porous version of an existing dielectric material, such as hydrogen silsesquioxane (HSQ), porous methyl silsesquioxane (MSQ), porous polyarylether (PAE), porous SiLK, or porous silicon oxide (SiO₂). In some embodiments, the gate dielectric layer 134 is deposited by a plasma enhanced chemical vapor deposition (PECVD) process or by a spin coating process.

Afterwards, a work function layer 136 is formed over the gate dielectric layer 134. In some embodiments, the thickness of the work function layer 136 is greater than the thickness of the gate dielectric layer 134. The work function layer 136 is made of metal material, and the metal material may include N-work-function metal or P-work-function metal. The N-work-function metal includes tungsten (W), copper (Cu), titanium (Ti), silver (Ag), aluminum (Al), titanium aluminum alloy (TiAl), titanium aluminum nitride (TiAlN), tantalum carbide (TaC), tantalum carbon nitride (TaCN), tantalum silicon nitride (TaSiN), manganese (Mn), zirconium (Zr) or combinations thereof. The P-work-function metal includes titanium nitride (TiN), tungsten nitride (WN), tantalum nitride (TaN), ruthenium (Ru) or combinations thereof.

After the work function layer 136 is formed, a gate electrode layer 138 is formed over the work function layer 136 as shown in FIG. 2C, in accordance with some embodiments. The gate electrode layer 138 is made of conductive material, such as aluminum (Al), copper (Cu), tungsten (W), titanium (Ti), tantalum (Ta), or other applicable materials.

The gate electrode layer 138 is formed by a deposition process, such as chemical vapor deposition (CVD), physical vapor deposition (PVD), atomic layer deposition (ALD), high density plasma CVD (HDPCVD), metal organic CVD (MOCVD), or plasma enhanced CVD (PECVD).

Afterwards, a portion of the gate dielectric layer 134, the work function layer 136 and the gate electrode layer 138 outside of the first trench 130 a and the second trench 130 b are removed by a removal process 11 as shown in FIG. 2D, in accordance with some embodiments. In some embodiments, the removal process 11 is a chemical mechanical polishing (CMP) process.

As a result, a first gate structure 132 a in the first region 11 is constructed by a first gate dielectric layer 134 a, a first work function layer 136 a and a first gate electrode layer 138 a formed in the first trench 130 a. A second gate structure 132 a in the second region 12 is constructed by a second gate dielectric layer 134 b, a second work function layer 136 b and a second gate electrode layer 138 b formed in the second trench 130 b. It should be noted that the area of the second gate electrode layer 138 b in the second region 12 is larger than the area of the first gate electrode layer 138 a in the first region 11.

The first gate structure 132 a and the second gate structure 132 b are transversely overlying a middle portion of the fin structure 110. A channel region is formed below the first gate structure 132 a and the second gate structure 132 b, and the channel region is wrapped by the first gate structure 132 a and the second gate structure 132 b.

It should be noted that the CMP process is performed on the first gate electrode layer 138 a in the first region 11 and the second gate electrode layer 138 b in the second region 12. The CMP process suffers an issue called “dishing effect”. The dishing effect is generated when the CMP process is performed on the metal layer formed over trenches having different width. The surface of the metal layer is recessed in a dish shape in a wider opening. Therefore, in order to reduce the dishing effect between the first region 11 and the second region 12, an etching process is performed on the first gate electrode layer 138 a and the second gate electrode layer 138 b after the CMP process.

As a result, the first gate electrode layer 138 a in the first region 11 is slightly recessed to form a first recess 160 a, and the second gate electrode layer 138 b in the second region 12 is recessed heavily to form a second recess 160 b. The depth of the second recess 160 b is greater than the depth of the first recess 160 a.

In some embodiments, the first recess 160 a has a first depth D₁ measured from a top surface of the first gate spacer 122 a to a top surface of the first gate electrode layer 138 a. In some embodiments, the second recess 160 b has a second depth D₂ measured from a top surface of the second gate spacer 122 a to a top surface of the second gate electrode layer 138 b. The second depth D₂ is greater than the first depth D₁.

For regions with different exposed areas (or etched areas), it is difficult to control etch uniformity due to the loading effect. Depending on the etching strategy, the loading effect is the etch rate for a larger area being either faster or slower than it is for a smaller area. In other words, the loading effect is that the etch rate in large area is mismatched the etch rate in small area. This means that the loading effect may be affected by the pattern density. Therefore, while etching the first work function layer 136 a in a first region 11 and the second work function layer 136 b in a second region 12, it is more difficult to control the uniformity of the etch depth.

In addition, as mentioned above, a top surface of the second gate electrode 138 b is lower than a top surface of the first gate electrode 138 a after the removal process 11. More specifically, more area of the second work function layer 136 b is exposed than the first work function layer 136 a because the removed portion of the second etched gate electrode layer 138′b is greater than that of the first etched gate electrode layer 138′a. Therefore, after the second etching process, the etched depth of the second work function layer 136 b may be more than the etched depth of the first work function layer 136 a due to the loading effect.

If more than a predetermined amount of the second work function layer 136 b in the second region 12 is removed, the breakdown voltage (Vbd) of the second gate structure 132 b may undesirably decrease. More specifically, if too much of the second work function layer 136 b is removed, the second work function layer 136 b may touch a top surface of the fin structure 110, the function of the second gate structure 132 b may fail. On the other hand, if less than the predetermined amount of the first work function layer 136 a in the first region 11 is removed, a gate-to-drain capacitance (Cgd) of the first gate structure 1 32 a may undesirably increase.

In order to resolve the above problems, a second etching process including a first plasma operation 13 a and a second plasma operation 13 b is performed. After the removal process 11, the second etching process is used to remove a portion of the first work function layer 136 a and a portion of the second work function layer 136 b.

The second etching process includes the first plasma operation 13 a as shown in FIG. 2E and the second plasma operation 13 b as shown in FIG. 2F, in accordance with some embodiments. The first plasma operation 13 a is configured to etch a portion of the first work function layer 136 a and a portion of the second work function layer 136 b, and the second plasma operation 13 a is configured to form a protection film 137 on the first work function layer 136 a and the second work function layer 136 b.

In some embodiments, the second etching process is operated at a temperature in a range from about 60 degrees to about 100 degrees. If the temperature is lower than 60 degrees, the etching rate may be too low, and more etching time is needed. Thus, the fabrication cost may increase. If the temperature is higher than 100 degrees, the etching rate may be too high. Thus, the etching amount is difficult to control and over-etching may occur.

In some embodiments, the second etching process is operated at a pressure in a range from about 1 mtorr to about 10 mtorr. If the pressure of the second etching process is lower than 1 mtorr, the etching rate is too low. If the pressure of the second etching process is higher than 80 mtorr, the etching uniformity is poor.

In some embodiments, the first plasma operation 13 a is performed by using a first plasma includes boron chloride (BCl₃), chlorine gas (Cl₂), oxygen (O₂) or combinations thereof. In some embodiments, the first plasma operation 13 a is performed at a power in a range from about 100 W to about 500 W. If the power is smaller than 100 W, the etching rate may be too low. If the power is greater than 500 W, the etching rate may be too fast, and the critical dimension (CD) is difficult to control.

After the first plasma operation 13 a is performed, the second plasma operation 13 b is performed on the first work function layer 136 a and the second work function layer 136 b as shown in FIG. 2F, in accordance with some embodiments. It should be noted that the first plasma operation 13 a and the second plasma operation 13 b are performed in the same chamber without transferring to another chamber, such that the pollution is reduced.

It should be noted that during the second plasma operation 13 b, the protection film 137 may temporarily form over the first work function layer 136 a and the second work function layer 136 b. The protection film 137 is used to prevent the second work function layer 136 b from being etched too much due to the loading effect.

In some embodiments, the second plasma operation 13 b is performed by using a second plasma comprising chlorine gas (Cl₂), hydrogen bromide (HBr), or combinations thereof. In some embodiments, the second plasma operation 13 b is performed at zero power. During the second plasma operation 13 b, the main function of the second plasma is to perform a deposition operation. The main function of the first plasma is to perform an etching operation.

When the bias power of the second plasma operation 13 b is set at zero, the gas generated from the second plasma may react with each other to form a polymer over the first work function layer 136 a and the second work function layer 136 b. The temporary polymer is used as a protection layer to prevent the second work function layer 136 b from being etched too much. Therefore, the loading effect between the first work function layer 136 a and the second work function layer 136 b is reduced.

FIG. 3 shows a bias power (W) versus an operation time (second) of the first plasma operation 13 a and the second plasma operation 13 b, in accordance with some embodiments. The first plasma operation 13 a is operated for a period of time t1, and the second plasma operation 13 b is operated for a period of time t2. In some embodiments, a ratio of the first period of time to the second period of time is in a range from about 1/4 to about 4/1. If the ratio is not within the above range, the loading effect may be serious.

It should be noted that the first plasma operation 13 a is operated at a bias power in a range from about 100 W to about 500 W, but the second plasma operation 13 b is operated at zero power. No etching operation is performed when the power is at zero value. Therefore, the loading effect may be reduced by performing the second plasma operation 13 b after the first plasma operation 13 a.

After the second plasma operation 13 b, the first etched work function layer 136′a and the second etched work function layer 136′b are obtained as shown in FIG. 2G, in accordance with some embodiments. In addition, a first via 162 a is formed over the first etched work function layer 136′a, and a second via 162 b is formed over the second etched work function layer 136′b.

In some embodiments, the first etched work function layer 136′a has a third height H₃ which is measured from a top surface of the isolation structure 114 to a top surface of the first etched work function layer 136′a. In some embodiments, the second etched work function layer 136′b has a fourth height H₄ which is measured from a top surface of the isolation structure 114 to a top surface of the second etched work function layer 136′b. In some embodiments, the third height H₃ is higher than the fourth height H₄. In some embodiments, a gap ΔH between the third height H₃ and the fourth height H₄ is in a range from about 1 nm to about 6 nm. In some embodiments, a gap ΔH between the third height H₃ and the fourth height H₄ is in a range from about 2 nm to about 4 nm.

In some embodiments, the first via 162 a has a third depth D₃ which is measured from a top surface of the first gate spacers 122 a to a top surface of the first etched work function layer 136′a. In some embodiments, the second via 162 b has a fourth depth D₄ which is measured from a top surface of the second gate spacers 122 b to a top surface of the second etched work function layer 136′b. In some embodiments, the third depth D₃ is greater than the fourth depth D₄. In some embodiments, a gap ΔH between the third depth D₃ and the fourth depth D₄ is in a range from about 1 nm to about 6 nm. In some embodiments, a gap ΔH between the third depth D₃ and the fourth depth D₄ is in a range from about 2 nm to about 4 nm.

After the second plasma operation 13 b and before a third etching process (as shown in FIG. 2G), the first plasma operation 13 a and the second plasma operation 13 b may be repeated until the gap ΔH between the first etched work function layer 136′a and the second etched work function layer 136′b reaches the predetermined value. One cycle includes performing the first plasma operation 13 a and the second plasma operation 13 b. In some embodiments, the cycle time is in a range from 0 to 10.

After the second etching process including the first operation 13 a and the second operation 13 b, a third etching process 15 is performed on the first gate dielectric layer 134 a in the first region 11 and the second gate dielectric layer 134 b in the second region 12 as shown in FIG. 2H, in accordance with some embodiments.

As a result, the first etched gate dielectric layer 134′a and the second etched gate dielectric layer 134′b are obtained after the third etching process 15. In some embodiments, the first etched gate dielectric layer 134′a has a fifth height H₅, and the second etched gate dielectric layer 134′b has a sixth height H₆. In some embodiments, the fifth height H₅ is equal to the sixth height H₆. The fifth height H₅ of the first etched gate dielectric layer 134′a is higher than the third height H₃ of the first etched work function layer 136′a. The sixth height H₆ of the second etched gate dielectric layer 134′b is higher than the fourth height H₄ of the second etched work function layer 136′b.

In addition, a top portion of the first gate dielectric layer 134 a is removed to form a first hole 164 a in the first region 11, and a top portion of the second gate dielectric layer 134 b is removed to form a second hole 164 b in the second region 12. In some embodiments, the first hole 164 a has a fifth depth D₅, and the second hole 164 b has a sixth depth D₆. In some embodiments, the fifth depth D₅ is equal to the sixth depth D₆.

After the third etching process 15, a fourth etching process 17 is performed on the first gate electrode layer 138 a and the second gate electrode layer 138 b as shown in FIG. 2I, in accordance with some embodiments. As a result, the first etched gate electrode layer 138′a and the second etched gate electrode layer 138′b are obtained. In some embodiments, the first etched gate electrode layer 138′a has a seventh height H₇, and the second etched gate electrode layer 138′b has an eighth height H₈. The seventh height H₇ is substantially equal to the eighth height H₈. The seventh height H₇ is higher than the fifth height H₅ of the first etched gate dielectric layer 134′a. The eighth height H₈ is higher than the sixth height H₆ of the second etched gate dielectric layer 134′b.

In addition, a top portion of the first gate electrode layer 138 is removed to form a first cavity 166 a in the first region 11, and a top portion of the second gate electrode layer 138 b is removed to form a second cavity 166 b in the second region 12. In some embodiments, the first cavity 166 a has a seventh depth D₇ and the second cavity 166 b has an eighth depth D₈. The seventh depth D₇ is equal to the eighth depth D₈.

After the fourth etching process 17, a first hard mask layer 152 a is formed on the etched gate structure 132′a, and a second hard mask layer 152 b is formed on the etched gate structure 132′b as shown in FIG. 2J, in accordance with some embodiments. The first hard mask layer 152 a has an uneven bottom surface and the second hard mask layer 152 a has an uneven bottom surface.

The first hard mask structure 152 a includes a first portion 154 a over the first etched gate dielectric layer 134′a, a second portion 156 a over the first etched work function layer 136′a and a third portion 158 a over the first etched gate electrode layer 138′a. The second hard mask structure 152 b includes a first portion 154 b over the second etched gate dielectric layer 134′b, a second portion 156 b over the second etched work function layer 136′b and a third portion 158 b over the second etched gate electrode layer 138′b.

In some embodiments, the first hard mask structure 152 a is formed by filling the first via 162 a, the first hole 164 a, and the first cavity 166 a with a dielectric material. The second hard mask structure 152 b is formed by filling the second via 162 b, the second hole 164 b, and the second cavity 166 b with a dielectric material.

In some embodiments, the hard mask structures 152 a, 152 b are made of silicon nitride. The hard mask structures 152 a, 152 b may be formed by using low-pressure chemical vapor deposition (LPCVD) or plasma enhanced chemical vapor deposition (PECVD), although other deposition processes may also be used in some other embodiments.

FIG. 4 shows a perspective representation of a FinFET device structure 100 b, in accordance with some embodiments of the disclosure. Semiconductor structure 100 b is similar to, or the same as, semiconductor structure 100 shown in FIGS. 1H and 2J, except the top surfaces of the first etched gate dielectric layer 134′a and the first etched work function metal layer 136′a are level. Processes and materials used to form semiconductor structure 100 b may be similar to, or the same as, those used to form semiconductor structure 100 and are not repeated herein.

As shown in FIG. 4, the top surface of the first etched gate electrode layer 138′a is higher than the top surface of the first etched work function layer 136′a, and the top surface of the second etched gate electrode layer 138′b is higher than the top surface of the second etched work function layer 136′b.

FIGS. 5A-5E show a perspective representations of various stages of forming a FinFET device structure 100 a, in accordance with some embodiments of the disclosure.

Referring to FIG. 5A, the first plasma operation 13 a is performed on the first work function layer 136 a and the second work function layer 136 b.

After the first plasma operation 13 a, the second plasma operation 13 b is performed as shown in FIG. 5B, in accordance with some embodiments of the disclosure. The protection films 137 are temporarily formed on the first work function layer 136 a and the second work function layer 136 b. The main function of the protection films 137 is to be used as protection to prevent the second work function layer 136 b being etched too much.

After the second plasma operation 13 b, a second cycle including the first plasma operation 13 a and the second plasma operation 13 b may be performed again. The loading effect may be gradually reduced by repeating the cycle. The time of the cycle may be adjusted according to the actual application.

Afterwards, top portions of the first gate dielectric layer 134 a and the second gate dielectric layer 134 b are removed by the third etching process 15 as shown in FIG. 5C, in accordance with some embodiments of the disclosure.

The first etched work function layer 136′a has a ninth height H₉, and the second etched work function layer 136′b has a tenth height H₁₀. The ninth height H₉ is smaller than the tenth height H₁₀. In some embodiments, a gap ΔH between the ninth height H₉ and the tenth height H₁₀ is in a range from about 1 nm to about 6 nm. In some embodiments, a gap ΔH between the ninth height H₉ and the tenth height H₁₀ is in a range from about 2 nm to about 4 nm. The first etched work function layer 136′a is level with the first etched gate dielectric layer 134′a.

After the third etching process 15, the fourth etching process 17 is performed to remove top portions of the first gate electrode layer 138 a and the second gate electrode layer 138 b as shown in FIG. 5D, in accordance with some embodiments of the disclosure.

After the fourth etching process 17, the first hard mask layer 152 a and the second hard mask layer 152 b are formed over the uneven surface of the first etched gate structure 132′a and the second etched gate structure 132′b as shown in FIG. 5E, in accordance with some embodiments of the disclosure.

When the loading effect between the first region 11 and the second region 12 is reduced, the third height H₃ (shown in FIG. 2G) of the first etched work function layer 136′a is lower than the fourth height H₄ of the second etched work function layer 136′b. Therefore, the gate-to-drain capacitance (Cgd) of the first gate structure 132 a is decreased, and the breakdown voltage (Vbd) of the second gate structure 132 b is increased. In addition, the first plasma operation and the second plasma operation is performed in-situ without transfer to different chamber.

Embodiments for forming a semiconductor device structure and method for formation the same are provided. A FinFET structure includes a first gate structure and a second gate structure formed over a fin structure over a substrate. The gate structure includes a gate dielectric layer, a work function layer and a gate electrode layer. The area of the second gate structure is greater than that of the first gate structure. In order to reduce the loading effect between two gate structures, when the work function layer is etched, a first plasma operation and a second plasma operation are sequentially performed on the work function layer. The bias power of the second plasma operation is set at zero value. Therefore, the gate-to-drain capacitance (Cgd) of the first gate structure is decreased, and the breakdown voltage (Vbd) of the second gate structure is increased. As a result, the performance of the FinFET device structure is improved.

In some embodiments, a FinFET device structure is provided. The FinFET device structure includes an isolation structure formed over a substrate and a fin structure formed over the substrate. The FinFET device structure includes a first gate structure and a second gate structure formed over the fin structure, and the first gate structure has a first width in a direction parallel to the fin structure, the second gate structure has a second width in a direction parallel to the fin structure, and the first width is smaller than the second width. The first gate structure includes a first work function layer having a first height which is measured from a top surface of the isolation structure to a top surface of the first gate structure. The second gate structure includes a second work function layer having a second height which is measured from a top surface of the isolation structure to a top surface of the second gate structure and a gap between the first height and the second height is in a range from about 1 nm to about 6 nm.

In some embodiments, a method for forming a FinFET device structure is provided. The method includes forming a fin structure over a substrate, and the substrate comprises a first region and a second region. The method includes forming a first dummy gate structure and a second dummy gate structure over the fin structure and forming an inter-layer dielectric (ILD) structure over the substrate and adjacent to the first dummy gate structure and the second dummy gate structure. The method also includes removing the first dummy gate structure and the second dummy gate structure to form a first trench and a second trench in the ILD structure and forming a first gate structure in the first trench and a second gate structure in the second trench. The first gate structure includes a first work function layer, and the second gate structure includes a second work function layer. The method further includes performing a first plasma operation on the first work function layer and the second work function layer for a first period of time and performing a second plasma operation on the first work function layer and the second work function layer for a second period of time. The first work function layer has a first height, and the second work function layer has a second height, and a gap between the first height and the second height is in a range from about 1 nm to about 6 nm.

In some embodiments, a method for forming a semiconductor device structure is provided. The method includes forming a fin structure over a substrate and forming a first dummy gate structure and a second dummy gate structure over the fin structure. The method also includes forming an inter-layer dielectric (ILD) structure over the substrate and adjacent to the dummy gate structure and removing the first dummy gate structure and the second dummy gate structure to form a first trench and a second trench in the ILD structure. The method also includes forming a first work function layer in the first trench and a second work function layer in the second trench and forming a first gate electrode layer over the first work function layer and a second gate electrode layer over the second work function layer. The method further includes removing a portion of the first work function layer and a portion of the second work function layer by an etching process. The etching process includes a first plasma operation and a second plasma operation, and the second plasma operation is performed at zero bias power.

One general aspect includes a fin field effect transistor (FINFET) device structure, including: an isolation structure formed over a substrate; a fin structure formed over the substrate; and a first gate structure and a second gate structure formed over the fin structure, where the first gate structure has a first width in a direction parallel to the fin structure, the second gate structure has a second width in a direction parallel to the fin structure, and the first width is smaller than the second width, and where the first gate structure includes a first work function layer and a gate electrode surrounded by the first work function layer and a step between a topmost surface of the gate electrode and a topmost surface of the first work function layer, the first work function layer having a first height which is measured from a top surface of the isolation structure to a top surface of the first gate structure; and the second gate structure includes a second work function layer and a second gate electrode surrounded by the second work function layer and a step between a topmost surface of the second gate electrode and a topmost surface of the second work function layer, the second work function layer having a second height which is measured from a top surface of the isolation structure to a top surface of the second gate structure.

Another general aspect includes a device including: a fin extending from a semiconductor substrate, the fin having a longitudinal axis in a first direction; a first gate stack extending over the fin and having a longitudinal axis orthogonal to the first direction, the first gate stack having a first width in the first direction and including a first gate dielectric layer having outermost sidewalls spaced apart by the first width, a first work function layer having outermost sidewalls spaced apart by a second width in the first direction less than the first width and having innermost sidewalls spaced apart by a third width in the first direction less than the second width, and a first gate electrode having outermost sidewalls spaced apart by the third width, where a topmost surface of the first gate electrode forms a step with a topmost surface of the first work function layer; and a second gate stack extending over the fin and having a longitudinal axis orthogonal to the first direction, the second gate stack having a fourth width in the first direction and including a second gate dielectric layer having outermost sidewalls spaced apart by a fifth width in the first direction, a second work function layer having outermost sidewalls spaced apart by a sixth width in the first direction less than the fifth width and having innermost sidewalls spaced apart by a seventh width in the first direction less than the sixth width, and a second gate electrode having outermost sidewalls spaced apart by the seventh width, where a topmost surface of the second gate electrode forms a step with a topmost surface of the second work function layer.

Yet another general aspect includes a device including: a fin field effect transistor (FINFET) device structure, including: an isolation structure formed over a substrate; a fin structure formed over the substrate; and a first gate structure and a second gate structure formed over the fin structure, where the first gate structure has a first width in a direction parallel to the fin structure, the second gate structure has a second width in a direction parallel to the fin structure, and the first width is smaller than the second width, and where the first gate structure includes a first gate dielectric layer, a first work function layer, a first gate electrode surrounded by the first work function layer, and a first capping layer, the first capping layer having a first thickness over the first gate dielectric layer, a second thickness over the first work function layer and a third thickness, less than the first thickness and the second thickness over the first gate electrode; the second gate structure includes a second gate dielectric layer second work function layer, a second gate electrode surrounded by the second work function layer, and a second capping layer overlying the second gate stack, the second capping layer having a fourth thickness over the first gate dielectric layer, a fifth thickness over the second work function layer and a sixth thickness, less than the fifth thickness and the sixth thickness, over the second gate electrode.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations here in without departing from the spirit and scope of the present disclosure. 

What is claimed is:
 1. A method comprising: forming a fin structure over a substrate; forming a first dummy gate structure and a second dummy gate structure over the fin structure; forming an inter-layer dielectric (ILD) structure over the substrate and adjacent to the first dummy gate structure and the second dummy gate structure; removing the first dummy gate structure to form a first trench in the ILD structure; removing the second dummy gate structure to form a second trench in the ILD structure; forming a first gate structure in the first trench and a second gate structure in the second trench, the first gate structure comprising a first work function layer and a first gate electrode layer, and the second gate structure comprising a second work function layer and a second gate electrode layer; removing portions of the first gate structure and the second gate structure outside of the first and second trenches; performing a first etch process on the first work function layer and the second work function layer, wherein after the first etch process the first work function layer has a top surface lower than a top surface of the first gate electrode layer, and wherein after the first etch process the second work function layer has a top surface lower than a top surface of the second gate electrode layer; after performing the first etch process, forming a protection film on the first work function layer and the second work function layer, wherein forming the protection film on the first work function layer and the second work function layer comprises performing a second plasma operation on the first work function layer and the second work function layer, the second plasma operation being performed by using a second plasma comprising chlorine gas (Cl₂), hydrogen bromide (HBr), or combinations thereof; and forming a first capping layer over the first gate structure and a second capping film over the second gate structure.
 2. The method of claim 1, wherein the performing the first etch process and the forming the protection film are performed in the same chamber.
 3. The method of claim 1, wherein performing the first etch process on the first work function layer and the second work function layer comprises performing a first plasma operation on the first work function layer and the second work function layer.
 4. The method of claim 3, wherein the first plasma operation is performed by using a first plasma comprising boron chloride (BCl₃), chlorine gas (Cl₂), oxygen (O₂) or combinations thereof.
 5. The method of claim 3, wherein the first plasma operation is operated at non-zero bias power and the second plasma operation is performed at zero bias power.
 6. The method of claim 1, wherein forming the first gate structure in the first trench comprises forming a first gate dielectric layer in the first trench, the first gate dielectric layer being between the first work function layer and the fin structure, a top surface of the first gate electrode layer being located at a position that is higher than a top surface of the first gate dielectric layer.
 7. The method of claim 6, wherein the top surface of the first gate dielectric layer is located at a position that is higher than a top surface of the first work function layer.
 8. The method of claim 1, wherein the first work function layer comprises a material selected from the group consisting of tungsten (W), copper (Cu), titanium (Ti), silver (Ag), aluminum (Al), titanium aluminum alloy (TiA₁), titanium aluminum nitride (TiA₁N), tantalum carbide (TaC), tantalum carbon nitride (TaCN), tantalum silicon nitride (TaSiN), manganese (Mn), zirconium (Zr), titanium nitride (TiN), tungsten nitride (WN), tantalum nitride (TaN), ruthenium (Ru), and combinations thereof.
 9. The method of claim 1, wherein the first capping layer has a planar top surface and a non-planar bottom surface.
 10. A method comprising: forming an inter-layer dielectric (ILD) structure over a substrate; forming a first trench in the ILD structure; forming a second trench in the ILD structure; forming a first gate structure in the first trench and a second gate structure in the second trench, the first gate structure comprising a first work function layer and a first gate electrode layer, and the second gate structure comprising a second work function layer and a second gate electrode layer; polishing the first gate structure and the second gate structure to have a top surface level with or below a top surface of the ILD structure; performing a first plasma operation on the first work function layer and the second work function layer, wherein after the first plasma operation the first work function layer has a top surface lower than a top surface of the first gate electrode layer, and wherein after the first plasma operation the second work function layer has a top surface lower than a top surface of the second gate electrode layer; after performing the first plasma operation, performing a second plasma operation on the first work function layer and the second work function layer, the second plasma operation forming a protection film on the first and second work function layers, the protection film being a polymer; and after performing the second plasma operation, depositing a first capping layer over the first gate structure and a second capping film over the second gate structure.
 11. The method of claim 10, wherein the first capping layer has a planar top surface and a non-planar bottom surface.
 12. The method of claim 10, wherein the first plasma operation and the second plasma operation are performed in the same chamber.
 13. The method of claim 10, wherein the first work function layer and the second work function layer have a same material composition.
 14. The method of claim 10 further comprising: after performing the second plasma operation, repeating the following operations: performing the first plasma operation on the first work function layer and the second work function layer; and performing the second plasma operation on the first work function layer and the second work function layer.
 15. The method of claim 10, wherein forming the first gate structure in the first trench and the second gate structure in the second trench comprises: conformally forming a first gate dielectric layer in the first trench and a second gate dielectric layer in the second trench; forming the first work function layer on the first gate dielectric layer in the first trench and the second work function layer in the second trench; and forming the first gate electrode layer on the first work function layer and the second gate electrode layer on the second work function layer.
 16. A method comprising: forming an inter-layer dielectric (ILD) structure over a fin; forming a first trench in the ILD structure; forming a second trench in the ILD structure; forming a first gate dielectric layer in the first trench and in the second trench; forming a first work function layer on the first gate dielectric layer in the first trench and in the second trench; and forming a first gate electrode layer on the first work function layer; polishing the first gate dielectric layer, the first work function layer, and the first gate electrode layer to form a first gate structure in the first trench and a second gate structure in the second trench, the first gate structure and the second gate structure each having a top surface level with or below a top surface of the ILD structure; performing a first plasma operation on the first work function layer, wherein after the first plasma operation, the first work function layer has a top surface lower than a top surface of the first gate electrode layer; after performing the first plasma operation, performing a second plasma operation on the first work function layer, the second plasma operation forming a protection film on the first work function layer; and after performing the second plasma operation, depositing a first capping layer over the first gate structure and a second capping film over the second gate structure, the first capping layer having a planar top surface and a non-planar bottom surface.
 17. The method of claim 16, wherein the top surface of the first gate dielectric layer is located at a position that is higher than a top surface of the first work function layer.
 18. The method of claim 1 further comprising: forming first gate spacers on opposing sides of the first dummy gate structure and second gate spacers on opposing sides of the second dummy gate structure, wherein after the first etch process, the first gate spacers have a top surface higher than the first gate electrode.
 19. The method of claim 1, wherein the protection film is a polymer.
 20. The method of claim 16, wherein the second plasma operation is performed by using a plasma comprising chlorine gas (Cl₂), hydrogen bromide (HBr), or combinations thereof. 